Suzuki RMX450Z User manual

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RMX450Z S/M 99500-44090-01E 2009.10.26 (Back: 18 mm) 5/0 DIC567 K
Printed in Japan
L0
L0
99500-44090-01E
SERVICE MANUAL
SERVICE MANUAL
RMX450Z
RMX450Z

FOREWORD
This manual contains an introductory description on the SUZUKI RMX450Z and procedures for its inspection/ser-
vice and overhaul of its main components.
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use
this section as well as other sections to use as a guide for proper inspection and service.
This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable
service.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2009
* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-
cations have been made since then, differences may exist between the content of this manual and the
actual motorcycle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures. They
may not represent the actual motorcycle exactly in detail.
* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for
servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
WARNING
!
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the
rider and passenger.

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1
2
3
4
5
6
9
Precautions............................................................... 00-i
Precautions............................................................ 00-1
General Information................................................... 0-i
General Information ...............................................0A-1
Maintenance and Lubrication.................................0B-1
Service Data...........................................................0C-1
Engine ......................................................................... 1-i
Precautions.............................................................. 1-1
Engine General Information and Diagnosis ...........1A-1
Emission Control Devices......................................1B-1
Engine Electrical Devices.......................................1C-1
Engine Mechanical.................................................1D-1
Engine Lubrication System ....................................1E-1
Engine Cooling System..........................................1F-1
Fuel System...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System.....................................................1K-1
Suspension................................................................. 2-i
Precautions.............................................................. 2-1
Suspension General Diagnosis..............................2A-1
Front Suspension...................................................2B-1
Rear Suspension....................................................2C-1
Wheels and Tires...................................................2D-1
Driveline / Axle ........................................................... 3-i
Precautions.............................................................. 3-1
Drive Chain / Drive Train / Drive Shaft...................3A-1
Brake ........................................................................... 4-i
Precautions.............................................................. 4-1
Brake Control System and Diagnosis ....................4A-1
Front Brakes...........................................................4B-1
Rear Brakes...........................................................4C-1
Transmission / Transaxle.......................................... 5-i
Precautions.............................................................. 5-1
Manual Transmission.............................................5B-1
Clutch.....................................................................5C-1
Steering....................................................................... 6-i
Precautions.............................................................. 6-1
Steering General Diagnosis...................................6A-1
Steering / Handlebar..............................................6B-1
Body and Accessories............................................... 9-i
Precautions.............................................................. 9-1
Wiring Systems......................................................9A-1
Lighting Systems....................................................9B-1
Combination Meter / Fuel Meter / Horn..................9C-1
Exterior Parts .........................................................9D-1
Body Structure .......................................................9E-1
TABLE OF CONTENTS

Table of Contents 00- i
00
Section 00
CONTENTS
Precautions
Precautions...............................................00-1
Precautions........................................................... 00-1
Warning / Caution / Note..................................... 00-1
General Precautions ...........................................00-1
Precautions for Electrical Circuit Service............ 00-2